1987 Kawasaki Tecate rebuild (lots of pics)

[ezmoney1979]

Hi everyone! Its time to finally post my 87 KXT (kind of long) story........ About 7 or so years ago I get a call from my friend (also neighbor). He says his friend needs some cash and wants to sell his three wheeler- " its green, two-stroke, 1987, runs and looks cool. Its got a big bore, extended swingarm, blah blah blah. He wants $500 for it." Knowing I am into three wheelers he says "you will want it." Although I didn't know much about Tecates at the time I say yeah I want it..... but I am kinda broke He says to help us both out he will spot me the cash I think I was at work or something but I came home to an 87 Tecate! Its front and rear fenders were destroyed but expertly stitched back together by what must have been the finest meth-head in the valley. The rear shock was blown (of course), it ran like crap, but it was intact and went through the gears. It had a DG pipe, decent shrouds, and an ok tank. I never met the guy who sold it so I had no history of the mods ect. just what was said on the first phone call. I took the carb off to find it still had the stock main jet in the mikuni (270 I think), so no wonder it ran like crap. I figure I would get it running good and go from there. I threw a much bigger main in it and got it to run better (still poor of course). I putted around on it just a little but decided to put it up before doing anymore damage to it (I could see cracks in the frame). So for the next few years it just sat behind my friends house, covered, waiting for me to revive it! Last year I decided it was time. This is what it looked like before I dissasembled it. I know what you all are thinking and the answer is no, I will not sell the super-mega hi-flow ported/polished petcock

[scooterroo]

nice start, good luck with the build. always like to see the green ones getting redone. whats your plans for it?

[ezmoney1979]

Well initially I wanted to go as OEM as possible, but that didnt really fit my budget.lol. So I decided to make a very nice dune bike that looks kinda stock. Mostly powder/polish everything and replace all seals and bearings and buy OEM plastic. This is the frame after getting it blasted. Many more cracks were revealed in the known problem areas (footpeg/ swingarm mount.) I also had to fix the grab bar mount area (stripped threads). While I had some (ok lots) of spare time I got started on polishing! This was my first time polishing aluminum so I was pretty stoked with the results.

[thestud25]

Looking good. I like shiney things!!

[Bretmd94]

Very nice, Money!

[Xpress]

Very VERY nice! I love it when you need to wear a pair of glasses just to see your polished parts

[ezmoney1979]

I remember it like it was yesterday......... UPS truck pulls up, dude gets out with huge box filled with new green plastic, I proceed to tear into it like a 10 year old spoiled brat at christmas.lol. I scored on the rear fenders. They were advertised as new with a seat that had been newly upholstered and new decals (although upside down). When they showed up there was a new stainless steel brace on them and all the rubber bumpers were in the seat base!! I still dont have a new right shroud but I should be getting one next week from a local guy that used to own a bike shop here. As it is the one I have is in ok shape its just had the top mounting tab repaired. I also ordered the 87 repro decal kit!

[fabiodriven]

Dude, how did you polish that stuff? I've tried like hell to do that and I have failed miserably.

[Xpress]

^Probably lots of fine steel wool to take all the crap off, then a lot of time with the polish, and a buffer. I'm subscribing to this. I'm interested to see the final product

[jpatey44]

where did you order the plastics from?

[scooterroo]

liking the progress. i like your case saver/ chain cover, is it aluminum as well? and is the swingarm an extended stock one? very nice job on the extension if so, and the polishing work too.

[ezmoney1979]

As far as the aluminum polishing goes I researched it a bit and just copied what everyone else was doing.(this site is awesome for that lol) Thanks 3ww! The swingarm and forks had major scratches and gouges that needed to be sanded out with a sander. I sanded every thing out (by hand) to about 1200-1600grit then threw it on a buffer with some white or green compound. To finish it off, good old Mothers aluminum polish! (which also works very good on gas tanks To achieve this level of shine I would also recommend having 1.Nothing to do 2.A patient wife/girlfriend 3.perhaps a sixer of your favorite IPA To be honest there was a bit of trial and error but I figure it was worth it. I think the tripples were the hardest to do (I never did get them as good as I wanted). Also before tackling the forks they need stripped of their clear coat. I used Ace paint stripper in an aerosol can.

[fabiodriven]

Do you need an angle grinder type setup to polish? Do you do it all by hand? Are there threads you can reference on here?

[ezmoney1979]

Fabio D- I just searched and I couldnt find the threads I was reading back when I did this, just bits and pieces. Some of the plastic sanding techniques remind me of aluminum No angle grinder! Nothing orbital until its a buffing wheel or buffer or you will just have more scratches to deal with. Some of the bad scratches I got rid of by using a small sander like a dual action 1/4 sheet with some 200grit, but that was only in the open areas. The rest was by hand in stages with the final stages wet sanding. It took lots of time!

[scooterroo]

hey any idea on the make of the rock guard? or is it a one of custom deal. i would love one of them.